Toyota RAV4 Service Manual: Reassembly (2005/11-2006/01)

Using sst and a press, press in the drive shaft
bearing to the inboard joint rh.

Sst 09527-10011, 09710-04081

Notice:

The bearing should be installed completely.

Using a snap ring expander, install a new drive shaft
hole snap ring.

Remove front drive shaft dust cover rh

Using sst and a press, press in a new drive shaft
dust cover until the distance from the tip of the
center drive shaft to the drive shaft dust cover
reaches the specification, as shown in the
illustration.

Sst 09527-10011

Standard distance:
104 +-0.5 Mm (4.09 +-0.02 In.)

Notice:

The dust cover should be installed
completely.

Be careful not to damage the dust cover.

Install front drive shaft dust cover lh

Using sst and a press, press in a new drive shaft
dust cover.

Sst 09527-10011

Notice:

The dust cover should be installed
completely.

Be careful not to damage the dust cover.

Install front drive shaft hole snap ring lh

Install a new hole snap ring.

Inspect front drive shaft

Install front axle outboard joint boot

Hint:

Before installing the boots, wrap the spline of the drive
shaft with vinyl tape to prevent the boots from being
damaged.

Install new parts to the outboard joint shaft in the
following order.

No. 2 Outboard joint boot clamp

Outboard joint boot

Outboard joint boot clamp

Pack the outboard joint shaft and boot with grease
from the boot kit.

Standard grease capacity:
190 to 200 g (6.7 To 7.1 Oz.)

Install front axle outboard joint boot lh no.2
Clamp

Caution:

Wear protective gloves while performing the
operation and be careful to avoid cutting your hands
or other body parts.

Install a new boot clamp to the outboard joint boot
and temporarily bend the lever.

Notice:

When temporarily bending the lever, make
sure not to deform the band and lever.

Set the clamp correctly in the guide groove
and align it with the interior of the vehicle as
much as possible.

With the joint on the working surface, use your body
weight to press down on the joint with one hand.

Then, roll the joint forward, as shown in the
illustration, and press the lever in until a "click"
sound is heard.

Notice:

Do not damage the deflector.

Make sure the joint is in full contact with the
joint surface at all times.

Using a plastic-faced hammer, fix the buckle into
place by tapping it. At the same time, use the
plastic-faced hammer to adjust the lift of the lever so
that the gaps between the buckle flange and lever
end flange become even.

Install front axle outboard joint boot no. 2
Clamp rh

Hint:

Use the same procedures described for the lh side.

Install front axle outboard joint boot clamp
lh

Caution:

Wear protective gloves while performing the
operation and be careful to avoid cutting your hands
or other body parts.

Install a new boot clamp to the outboard joint boot
and temporarily bend the lever.

Notice:

When temporarily bending the lever, make sure
not to deform the band and lever.

Using water pump pliers, temporarily lock the boot
clamp by clamping it down until a "click" sound is
heard.

Using a plastic-faced hammer, fix the buckle into
place by tapping it. At the same time, use the
plastic-faced hammer to adjust the lift of the lever so
that the gaps between the buckle flange and lever
end flange become even.

Notice:

Do not strike the drive shaft forcefully with the
plastic-faced hammer.

Install front axle outboard joint boot
clamp rh

Hint:

Use the same procedures described for the lh side.

Install front drive shaft damper lh

Hint:

Install the damper clamp to the outboard joint side.

Install a new drive shaft damper clamp and the drive
shaft damper to the drive shaft.

Make sure that the damper is on the shaft groove.

Set the distance, as described below.

Standard distance:
161 to 165 mm (6.339 To 6.496 In.)

Install front drive shaft damper clamp lh

Hold the front drive shaft lightly in a soft vise.

Install the drive shaft damper clamp to the damper.

Notice:

Be sure to install the clamp in the correct
position.

One touch type:

Using a screwdriver, install the drive shaft
damper clamp, as shown in the illustration.

Claw engagement type:

Using needle-nose pliers, install the drive shaft
damper clamp, as shown in the illustration.

Install front drive shaft damper rh

Hint:

Install the damper clamp to outboard joint side.

Install a new drive shaft damper clamp and the drive
shaft damper to the drive shaft.

Make sure that the damper is on the shaft groove.

Set the distance, as described below.

Standard distance:
161 to 165 mm (6.339 To 6.496 In.)

Install front drive shaft damper clamp rh

Hold the front drive shaft lightly in a soft vise.

Install the drive shaft damper clamp to the damper.

Notice:

Be sure to install the clamp in the correct
position.

One touch type:

Using a screwdriver, install the drive shaft
damper clamp, as shown in the illustration.

Claw engagement type:

Using needle-nose pliers, install the drive shaft
damper clamp, as shown in the illustration.

Install front drive inboard joint assembly lh

Wrap the spline of the outboard joint shaft with vinyl
tape to prevent the boots from being damaged.

Install new parts to the outboard joint shaft in the
following order.

Inboard joint boot clamp

No. 2 Inboard joint boot clamp

Inboard joint boot

Place the beveled side of the tripod axial spline
toward the outboard joint.

Align the matchmarks placed before removal.

Using a brass bar and hammer, tap the tripod joint
onto the drive shaft.

Notice:

Do not tap the rollers.

Be sure to install the tripod joint in the correct
direction

Pack the inboard joint shaft and boot with grease
from the boot kit.

Standard grease capacity:
175 to 185 g (6.2 To 6.5 Oz.)

Using a snap ring expander, install a new shaft snap
ring.

Align the matchmarks, and install the inboard joint to
the outboard joint shaft.

Install front drive inboard joint assembly
rh

Hint:

Use the same procedures described for the lh side.

Install front axle inboard joint boot

Install the inboard joint boot to the inboard joint.

Install front axle inboard joint boot clamp lh

One touch type:

Using a screwdriver, install the inboard joint
boot clamp, as shown in the illustration.

Notice:

Be careful not to damage the boot.

Claw engagement type:

Using needle-nose pliers, install the inboard
joint boot clamp, as shown in the illustration.

Notice:

Be careful not to damage the boot.

Install front axle inboard joint boot
clamp rh

Hint:

Use the same procedures described for the lh side.

Install front axle inboard joint boot no. 2
Clamp lh

One touch type:

Using a screwdriver, install the no. 2 Inboard
joint boot clamp, as shown in the illustration.

Notice:

Be careful not to damage the boot.

Claw engagement type:

Using needle-nose pliers, install the no. 2
Inboard joint boot clamp, as shown in the
illustration.

Notice:

Be careful not to damage the boot.

Install front axle inboard joint boot no. 2
Clamp rh

Hint:

Use the same procedures described for the lh side.

Inspect front drive shaft

Check that there is no severe play in the radial
direction of the outboard joint.

Check that the inboard joint slides smoothly in the
thrust direction.

Check that there is no severe play in the radial
direction of the inboard joint.

System voltage
Description
The battery supplies electricity to the ecm even when the ignition switch is
in the off position. This
power allows the ecm to store data such as dtc history, freeze frame data and
fuel trim values. If the
battery voltage falls below a minimum level, the memory is cleared and ...